Systems and assemblies for cooling server racks

ABSTRACT

A cooling assembly for cooling server racks includes a server rack enclosure sub-assembly that includes at least one panel member defining a volume for receiving one or more server racks having a front portion and a rear portion, at least one of the panel members is a rear panel member; at least one frame member defines an opening for receiving the rear portion of the server racks to form a hot space between the rear panel member and the combination of the frame member and the rear portion of the server racks; a cooling sub-assembly disposed in thermal communication with the hot space to cool at least one server supported in the server rack and including a chassis receiving at least one heat exchange member for exchanging heat between a refrigerant fluid flowing through the heat exchange member and fluid flowing through the hot space heated by the server.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 16/653,509 filed Oct. 15, 2019, now U.S. Pat. No. 11,602,074, which is a continuation of U.S. patent application Ser. No. 15/590,596 filed May 9, 2017, now U.S. Pat. No. 10,448,539, which is a continuation of U.S. patent application Ser. No. 14/216,005 filed on Mar. 17, 2014, now U.S. Pat. No. 9,648,784 which claims the benefit of, and priority to, U.S. Provisional Patent Application No. 61/802,267 filed on Mar. 15, 2013, the entire contents of each of which are incorporated herein by reference.

BACKGROUND

Due to the generation of large quantities of heat by electronics contained within data center server racks, large amounts of power are consumed for cooling of server racks. In the first decade of the 2000 millennium, data centers have consequently become one the largest consumers of electrical power in the United States and elsewhere around the world. In addition to the environmental consequences, the large power consumption is a major operating cost of a data center and requires large cooling equipment that takes space that could otherwise be used for installation of data servers.

SUMMARY

The embodiments of the present disclosure are directed to a cooling assembly and system for cooling server racks that reduce the power consumption required for cooling of server racks and makes available space for the installation of additional data servers. The cooling assembly and system for cooling server racks may be deployed for the installation of new server racks in a new data center. The present disclosure relates also to a cooling assembly and system that is retrofittable for cooling existing server racks in an existing data center.

More particularly, in one aspect, the present disclosure relates to a cooling assembly for cooling server racks that includes: a server rack enclosure sub-assembly that includes at least one panel member defining a volume for receiving one or more server racks having a front portion and a rear portion. At least one of the one or more panel members is a rear panel member. At least one frame member defines an opening for receiving the rear portion of the one or more server racks to form a hot space between the rear panel member and the combination of the at least one frame member and the rear portion of the one or more server racks. A cooling sub-assembly is disposed in thermal communication with the hot space to enable cooling of at least one server supported in the server rack. The cooling sub-assembly includes a chassis configured to receive at least one heat exchange member for exchanging heat between a refrigerant fluid flowing through the heat exchange member and fluid flowing through the hot space that has been heated by the server.

In one exemplary embodiment, the frame member includes one or more horizontal frame members, one or more vertical frame members, or both.

In yet another exemplary embodiment, at least one of the one or more horizontal frame members is supported by one or more of the one or more vertical frame members. In one exemplary embodiment, one or more of the one or more vertical frame members or one or more of the one or more horizontal members or both the one or more of the one or more vertical frame members and the one or more of the one or more horizontal frame members further includes a sealing member to form a seal between the frame member and the rear portion of the server rack.

In still another exemplary embodiment, the frame member includes an impermeable material. In one exemplary embodiment, the impermeable material is selected from the group consisting of foam, rubber, and neoprene. In yet another exemplary embodiment, the frame member includes a selectively permeable material. In another exemplary embodiment, the selectively permeable material includes a brush assembly.

In a still further exemplary embodiment, the rear panel member includes at least one door to enable access to the rear portion of the one or more server racks.

In yet another exemplary embodiment, the chassis includes a set of one or more structural members configured and disposed to support the heat exchange member. The set of one or more structural members support the heat exchange member to enable the thermal communication with the server rack enclosure sub-assembly for the cooling of the server.

In one exemplary embodiment, the set of one or more frame members is configured and disposed to support at least one refrigerant fluid supply line and at least one refrigerant fluid return line. The refrigerant fluid supply line and the refrigerant fluid return line are in thermal and fluid communication with the heat exchange member.

In another exemplary embodiment, the set of one or more structural members is configured and disposed to support at least one forced convection cooling member in fluid communication with the heat exchange member to enable the cooling of the server. In still another exemplary embodiment, the forced convection cooling member includes a plurality of fans that are disposed to draw the hot fluid flowing in the hot space through the heat exchange member and over the top of the cooling enclosure subassembly.

In an alternative exemplary embodiment, the cooling assembly further includes a second server rack enclosure sub-assembly. The second server rack enclosure sub-assembly is configured to receive one or more server racks configured to support at least one server. The second server rack enclosure sub-assembly defines a frontal position with respect to the server rack and a rear position with respect to the server rack. The second server rack enclosure sub-assembly includes at least one panel member configured and disposed to selectively seal the rear position of the second server rack enclosure sub-assembly. A second cooling sub-assembly is disposed in thermal communication with the second server rack enclosure sub-assembly to enable cooling of the server when the server is supported in the server rack. The second server rack enclosure sub-assembly and the second cooling sub-assembly define a second confined hot space disposed between the panel member configured and disposed to selectively seal the rear position of the second server rack enclosure sub-assembly and the rear position of the one or more server racks enclosed therein. The second cooling sub-assembly includes structure configured to receive at least one heat exchange member for exchanging heat between a refrigerant fluid flowing through the heat exchange member and heated air or gas that removes heat from the server and which flows through the confined hot space. The first cooling sub-assembly and the second cooling sub-assembly each include the heat exchange members for exchanging heat between a refrigerant fluid flowing through the heat exchange member and heated air or gas that removes heat from the server. The first cooling sub-assembly and the second cooling sub-assembly each include a fluid section configured to enable fluid and thermal communication with the respective heat exchange member and define a first end and a second end. Each end enables the thermal communication. The first end of the fluid section of the second cooling sub-assembly is configured to couple in series with the second end of the fluid section of the first cooling sub-assembly to form a chain of cooling sub-assemblies.

In a further exemplary embodiment, the first and second fluid sections each further define respective electrical sections having first and second ends. The first end of the second electrical section is configured to enable electrical communication with the second end of the first electrical section.

In another aspect, the present disclosure relates also to a cooling sub-assembly for a cooling assembly for cooling server racks. The cooling assembly includes a server rack enclosure sub-assembly. The server rack enclosure sub-assembly is configured to receive one or more server racks configured to support at least one server. The server rack enclosure sub-assembly defines a frontal position with respect to the server rack and a rear position with respect to the server rack. The server rack enclosure sub-assembly includes at least one panel member configured and disposed to selectively seal the rear position of the server rack enclosure sub-assembly. The cooling sub-assembly is disposed in thermal communication with the server rack enclosure sub-assembly to enable cooling of the server when the server is supported in the server rack. The server rack enclosure sub-assembly and the cooling sub-assembly define a confined hot space disposed between the panel member configured and disposed to selectively seal the rear position of the server rack enclosure sub-assembly and the rear position of the one or more server racks. The cooling sub-assembly includes structure configured to receive at least one heat exchange member for exchanging heat between a refrigerant fluid flowing through the heat exchange member and heated air or gas that removes heat from at least one server. The structure is configured and disposed to support at least one forced convection cooling member in fluid communication with the heat exchange member to enable the cooling of the server when the server is supported in the server rack.

In one exemplary embodiment, the structure includes a set of one or more frame members configured and disposed to retain the heat exchange member. The set of one or more frame members support the heat exchange member to enable the thermal communication with the server rack enclosure sub-assembly for the cooling of the server when the server is supported in the server rack.

In still another exemplary embodiment, the set of one or more frame members is configured and disposed to support at least one refrigerant fluid supply line and at least one refrigerant fluid return line. The refrigerant fluid supply line and the refrigerant fluid return line are in thermal and fluid communication with the heat exchange member.

In a further exemplary embodiment, the set of one or more frame members is configured and disposed to support at least one forced convection cooling member in fluid communication with the heat exchange member to enable the cooling of the server when the server is supported in the server rack.

In still another aspect, the present disclosure relates also to a system for cooling server racks including a cooling assembly that includes a server rack enclosure sub-assembly. The server rack enclosure sub-assembly is configured to receive one or more server racks configured to support at least one server. The server rack enclosure sub-assembly defines a frontal position with respect to the server rack and a rear position with respect to the server rack. The server rack enclosure sub-assembly includes at least one panel member configured and disposed to selectively seal the rear position of the server rack enclosure sub-assembly. A cooling sub-assembly is disposed in thermal communication with the server rack enclosure sub-assembly to enable cooling of the server when the server is supported in the server rack. The server rack enclosure sub-assembly and the cooling sub-assembly define a confined hot space disposed between the panel member configured and disposed to selectively seal the rear position of the server rack enclosure sub-assembly and the rear position of the one or more server racks. The cooling sub-assembly includes structure configured to receive at least one heat exchange member for exchanging heat between a refrigerant fluid flowing through the heat exchange member and heated air or gas that removes heat from the server and which flows through the confined hot space. A central cooling circuit is in thermal communication with the heat exchanger of the cooling sub-assembly. The central cooling circuit is configured to remove heat transferred to the refrigerant fluid.

In one exemplary embodiment, the structure includes a set of one or more frame members configured and disposed to retain the heat exchange member. The set of one or more frame members support the heat exchange member to enable the thermal communication with the server rack enclosure sub-assembly for the cooling of the server when the server is supported in the server rack.

In still another exemplary embodiment, the set of one or more frame members is configured and disposed to support at least one refrigerant fluid supply line and at least one refrigerant fluid return line. The heat exchange member is in fluid and thermal communication with the central cooling circuit via the refrigerant fluid supply line and the refrigerant fluid return line.

In yet another exemplary embodiment, the set of one or more frame members is configured and disposed to support at least one forced convection cooling member in fluid communication with the heat exchange member to enable the cooling of the server when the server is supported in the server rack.

In yet another exemplary embodiment, the system further includes a second server rack enclosure sub-assembly. The second server rack enclosure sub-assembly is configured to receive one or more server racks configured to support at least one server. The second server rack enclosure sub-assembly defines a frontal position with respect to the server rack and a rear position with respect to the server rack. The second server rack enclosure sub-assembly includes at least one panel member configured and disposed to selectively seal the rear position of the second server rack enclosure sub-assembly. A second cooling sub-assembly is disposed in thermal communication with the second server rack enclosure sub-assembly to enable cooling of the server when the server is supported in the server rack. The second server rack enclosure sub-assembly and the second cooling sub-assembly define a second confined hot space disposed between the panel member configured and disposed to selectively seal the rear position of the second server rack enclosure sub-assembly and the rear position of the one or more server racks enclosed therein. The second cooling sub-assembly includes structure configured to receive at least one heat exchange member for exchanging heat between a refrigerant fluid flowing through the heat exchange member and heated air or gas that removes heat from the server and which flows through the confined hot space. The first cooling sub-assembly and the second cooling sub-assembly each include the heat exchange members for exchanging heat between a refrigerant fluid flowing through the heat exchange member and heated air or gas that removes heat from the server. The first cooling sub-assembly and the second cooling sub-assembly each include a fluid section configured to enable fluid and thermal communication with the respective heat exchange member and define a first end and a second end. Each end enables the thermal communication. The first end of the fluid section of the second cooling sub-assembly is configured to couple in series with the second end of the fluid section of the first cooling sub-assembly to form a chain of cooling sub-assemblies.

In still another exemplary embodiment, the first and second fluid sections each further define respective electrical sections having first and second ends. The first end of the second electrical section is configured to enable electrical communication with the second end of the first electrical section.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the present disclosure are described with reference to the accompanying drawings wherein:

FIG. 1 is a perspective view of one embodiment a cooling assembly according to the present disclosure that illustrates a frontal view of server racks in enclosures that are received within the cooling assembly;

FIG. 2 is a perspective view of one embodiment of a cooling assembly according to the present disclosure that illustrates a rear view of the cooling assembly that includes rear panel members that forms a hot space between the rear panel member and the rear portion of server racks;

FIG. 3A is a plan view of the cooling assembly of FIG. 1 ;

FIG. 3B is an elevation view of the cooling assembly of FIG. 1 and FIG. 3A as viewed from the frontal position;

FIG. 3C is a side elevation view of the cooling assembly of FIG. 1 and FIGS. 3A and 3C;

FIG. 4A is a perspective partial view of a server rack enclosure sub-assembly from a frontal position that is included within the cooling assembly of FIG. 2 ;

FIG. 4B is a detailed view of a connection between a vertical frame member and a horizontal frame member included within the server rack enclosure sub-assembly of FIG. 4B;

FIG. 5A is a perspective partial view from a rear position of the server rack enclosure sub-assembly of FIG. 4A that is included within the cooling assembly of FIG. 2 ;

FIG. 5B is a detailed view of a connection between vertical frame members and horizontal frame members included within the server rack enclosure sub-assembly of FIG. 5B;

FIG. 6 is a perspective view of a portion of the server rack enclosure sub-assembly of FIGS. 5A and 5B that is included within the cooling assembly of FIG. 1 or 2 illustrating sealing members that partially form the hot space;

FIG. 7A is another perspective view of a portion of the server rack enclosure sub-assembly of FIG. 6 that is included within the cooling assembly of FIG. 1 or 2 illustrating sealing members that partially form the hot space;

FIG. 7B is a detailed view of a hinge member illustrated in FIG. 7A;

FIG. 7C is a detailed view of another hinge member illustrated in FIG. 7A;

FIG. 8A is a perspective view of the server rack enclosure sub-assembly that includes rear panel members that at least partially form the hot space;

FIG. 8B is a detailed view of a hinge member illustrated in FIG. 8A;

FIG. 8C is detailed view of another hinge member illustrated in FIG. 8A;

FIG. 9A is a perspective view of one embodiment of a cooling sub-assembly according to the present disclosure that is in thermal communication with the hot space as viewed from an upper vantage point;

FIG. 9B is a perspective view of the cooling sub-assembly of FIG. 9A as viewed from a lower vantage point;

FIG. 9C is another perspective view of the cooling sub-assembly of FIG. 9A as viewed from another upper vantage point;

FIG. 9D is another perspective view of the cooling sub-assembly of FIG. 9A as viewed from another lower vantage point;

FIG. 10 is a perspective exploded view of the cooling sub-assembly of FIGS. 9A to 9D;

FIG. 11 is a partial perspective view the cooling sub-assembly mounted above the server rack enclosure sub-assembly;

FIG. 12A is a perspective view of one embodiment of a shroud member according to the present disclosure that is operably coupled to the cooling assembly;

FIG. 12B is another perspective view of the shroud member of FIG. 12A;

FIG. 13 is a perspective view of multiple cooling assemblies from an upper vantage point;

FIG. 14 is a cross-sectional view of the cooling assembly;

FIG. 15 is a schematic diagram of a cooling system for cooling server racks that includes a plurality of cooling assemblies and a central cooling circuit according to one embodiment of the present disclosure;

FIG. 16A is a perspective view of a plurality of cooling sub-assemblies for cooling servers in server racks according to another embodiment of the present disclosure;

FIG. 16B is an elevation end view of the plurality of cooling sub-assemblies of FIG. 16A; and

FIG. 16C is an elevation view of the plurality of cooling sub-assemblies of FIGS. 16A and 16B.

DETAILED DESCRIPTION

The present disclosure relates to an air flow distribution system for server racks that significantly reduces the power requirements for cooling server racks within data centers.

Various embodiments of the present disclosure are described with reference to the accompanying drawings as follows.

FIGS. 1-14 describe one or more cooling assemblies for cooling server racks according to embodiments of the present disclosure. Referring particularly to FIG. 1 , there is disclosed one embodiment of a cooling assembly 1000 according to the present disclosure that illustrates a frontal view of server racks (not directly visible) in enclosures 1010 a, 1010 b . . . 1010 n that are received within the cooling assembly 1000. The enclosures 1010 a, 1010 b . . . 1010 n include sealing members 1020 a, 1020 b . . . 1020 n that may include perforated doors that allow the flow of air to flow through to enable cooling of the servers (not shown) in the server racks (not shown) inside of the enclosures 1010 a, 1010 b . . . 1010 n. The sealing members 1020 a, 1020 b . . . 1020 n define a proximal or frontal portion of the enclosures 1010 a, 1010 b . . . 1010 n. The enclosures 1010 a, 1010 b . . . 1010 n also define a rear portion 1022 a, 1022 b . . . 1022 n, such as a perforated screen, as illustrated by the dashed line in FIG. 3C. Referring particularly to FIGS. 1 and 2 , the cooling assembly 1000 includes a server rack enclosure sub-assembly 1100 and a cooling sub-assembly 1200. Control boxes 1410 and 1420, positioned on a rear side of cooling sub-assembly 1200, are described in more detail below with respect to FIG. 10 . The server rack enclosure sub-assembly 1100 includes one or more first side panel members 1110 and 1112 and as illustrated in FIG. 3C one or more second side panel members 1120 and 1122. Specifically, first and second side panel members 1110 and 1120 are proximal panel members with respect to the frontal portions defined by the sealing members 1020 a, 1020 b . . . 1020 n while first and second side panel members 1112 and 1122 are distal panel members with respect to the sealing members 1020 a, 1020 b . . . 1020 n.

As best illustrated in FIG. 2 , the server rack enclosure sub-assembly 1100 also includes rear panel members 1130 a and 1130 b that correspond to rear portions 1022 a, 1022 b . . . 1022 n (additional adjacent rear panel members corresponding to rear portions through 1022 n are not shown).

As best illustrated in FIG. 2 , FIG. 13 and FIG. 14 , the side panel members 1110, 1120, the rear panel members 1130 a, 1130 b and the side panel members 1112, 1122 define volumes 1140 a, 1140 b, 1140 c, 1140 d, 1140 e, 1140 f . . . for receiving one or more server racks.

As best illustrated in FIG. 3C and FIG. 14 , rear portions 1022 a, 1022 b . . . 1022 n, of the enclosures 1010 a, 1010 b . . . 1010 n are received within the respective volumes 1140 a, 1140 b, 1140 c, 1140 d, 1140 e, 1140 f . . . . to form hot spaces 1150 a, 1150 b, . . . 1150 n between the respective rear panel members 1130 a and 1130 b . . . and the rear portions rear portions 1022 a, 1022 b . . . 1022 n of the respective enclosures 1010 a, 1010 b . . . 1010 n.

Referring to FIGS. 4A-8C, and as best illustrated in FIGS. 4A and 4B, the one or more first side panel members 1110 and 1112, the one or more second side panel members 1120 and 1122, and the rear panel members 1130 a and 1130 b are supported by at least one frame member assembly 1160 that may include one or more lower horizontal frame members 1162, 1164 and 1166 and one or more upper horizontal frame members 1172, 1174 and 1176. The lower horizontal frame members 1162 and 1164 may be orthogonal to the lower horizontal frame member 1166, which is distal with respect to the sealing members 1020 a, 1020 b . . . 1020 n.

The upper horizontal frame members 1172, 1174 and 1176 may be supported by respective vertical frame members 1182 a, 1182 b, 1182 c, and 1184 a, 1184 b, 1184 c and 1186. The upper horizontal frame members 1172 and 1174 may be orthogonal to the upper horizontal frame member 1176, which is also distal with respect to the sealing members 1020 a, 1020 b . . . 1020 n.

The upper horizontal frame members 1172 and 1174 and the upper horizontal frame member 1176 respectively may overlap the lower horizontal frame members 1162 and 1164 and the lower horizontal frame member 1166.

The respective vertical frame members 1182 a, 1182 b, 1182 c, and 1184 a, 1184 b, 1184 c and 1186 may be supported by the one or more lower horizontal frame members 1162, 1164 and 1166.

Additional upper horizontal frame members 1176 a, 1176 b may link and interconnect with upper horizontal frame members 1172 and 1174 at the intersections 1172′, 1172″ with vertical support members 1182 a, 1182 b and at the intersections 1174′, 1174″ with vertical support members 1184 a, 1184 b, respectively.

A ladder type structure 1190, that includes a proximal vertical member 11901 and a distal vertical member 11902, may be vertically mounted and intersects with and supports upper horizontal cross frame members 1176 b and 1176 at intersections 1190 b, 1190′ to partially form a partition within the volume 1140 a to form a first sub-volume 1140 a 1 and a second sub-volume 1140 a 2.

As best illustrated in FIGS. 5A and 5B, the frame assembly 1160 may further include a front upper air baffle 1178 b 1 and a rear upper air baffle 1178 b 2 that each traverse or span the frame assembly 1160 between the upper horizontal orthogonal frame members 1172 and 1174.

As best illustrated in FIG. 6 , and partially illustrated in FIGS. 7A and 8A, the frame member assembly 1160 may further include one or more sealing members 1192 in the vicinity of the front upper air baffle 1178 b 1 and rear upper air baffle 1178 b 2 to form a seal between the frame member assembly 1160 and the rear portions 1022 a, 1022 b, . . . 1022 n of the enclosures 1010 a, 1010 b . . . 1010 n of the server racks. Thus the sealing members 1192 at least partially confine and at least partially seal the hot spaces 1150 a, 1150 b, . . . 1150 n between the respective rear panel members 1130 a and 1130 b . . . and the rear portions 1022 a, 1022 b . . . 1022 n of the respective enclosures 1010 a, 1010 b . . . 1010 n.

More particularly, sealing members 1192 include seal members 11921, 11923, 11925 and 11926 that are mounted along vertical frame members 1184 c, 1186, 11902 and 1182 c, respectively.

In one embodiment, as illustrated, the seal member 11922 is mounted horizontally downward along upper horizontal distal frame member 1176 between the vertical frame member 1184 c and the distal vertical member 11902 of the ladder-type structure 1190. Additionally, seal member 1194 may be mounted horizontally downward along upper horizontal distal frame member 1176 between the distal vertical member 11902 of the ladder-type structure 1190 and the vertical frame member 1182 c.

As illustrated in FIGS. 6, 7A and 7B, the seal members 1192 may be selectively permeable to allow penetration by personnel such as when personnel insert an arm through the seal members such that sealing members 1192 are made from a selectively permeable material. The selectively permeable seal members 1192 may be formed as brush assemblies.

Alternatively, the sealing members 1192 may be made from an impermeable material. In one embodiment, the impermeable material includes a material selected from the group consisting of foam, rubber, and neoprene.

As illustrated in FIGS. 4A, 5A and 8A, an additional lower horizontal frame member 1168 that is disposed parallel to and proximally with respect to lower horizontal frame member 1166 extends orthogonally between, and is coupled to, lower horizontal frame member 1162 and lower horizontal frame member 1164. Frame member 1168 prevents air bypass under the server cabinet (not shown) and also restricts the positioning of the server cabinet (not shown) within the server rack enclosure sub-assembly 1100, thereby maintaining the hot spaces 1150 a, 1150 b, . . . 1150 n (see FIG. 3C).

In one embodiment, as best illustrated in FIG. 2 and FIG. 8A, the rear panel members 1130 a and 1130 b are at least partially configured as at least one door to enable access to the hot spaces 1150 a, 1150 b, . . . 1150 n between the respective rear panel members 1130 a and 1130 b . . . and the rear portions 1022 a, 1022 b . . . 1022 n of the respective enclosures 1010 a, 1010 b . . . 1010 n. The location and details of upper frame hinge members 1132 a and 1132 b and lower frame hinge members 1134 a and 1134 b for rear panel members 1130 a and 1130 b, respectively, are illustrated in FIGS. 7A, 7B and 7C. Additionally, the assembly of door upper hinge members 1132 a′ and 1132 b′ and door lower hinge members 1134 a′ and 1134 b′ of rear panel members 1130 a and 1130 b, respectively, to form upper hinges 1136 a and 1136 b and lower hinges 1138 a and 1138 b of rear panel members 1130 a and 1130 b, respectively, is illustrated in FIGS. 8A, 8B and 8C.

As described above, referring now to FIGS. 9A to 11 , in addition to server rack enclosure sub-assembly 1100, the cooling assembly 1000 includes cooling sub-assembly 1200 that is disposed in thermal communication with the hot spaces 1150 a, 1150 b, . . . 1150 n between the respective rear panel members 1130 a and 1130 b . . . and the rear portions rear portions 1022 a, 1022 b . . . 1022 n of the respective enclosures 1010 a, 1010 b . . . 1010 n to enable cooling of the servers (not shown) in the server racks (not shown) inside of the enclosures 1010 a, 1010 b . . . 1010 n.

The cooling sub-assembly or chassis 1200 is configured to receive one or more heat exchange members. In one exemplary embodiment, the cooling sub-assembly 1200 defines a proximal portion 1212 and a distal portion 1214 and a first end 1201 and a second end 1202. The chassis 1200 includes an upper supporting frame member 1210 which includes a rectangularly-shaped upper edge surface member 1220, a lateral edge member 1222, and a forced-convection receiving member 1224 that interconnects the upper edge surface member 1220 and the lateral edge member 1222. The forced convection receiving member 1224 defines a slope at an angle Θ with respect to the upper edge surface member 1220 (or with respect to the horizontal direction X illustrated in FIG. 9A). The forced-convection receiving member 1224 defines an aperture 1224′, that is exemplarily illustrated as rectangularly-shaped, to receive a plurality of forced-convection members 1250, e.g., motor-driven fans, that are mounted on a supporting plate member 1252 to enable flow of air forced through the aperture 1224′ and the plurality of forced convection members 1250 (see FIG. 10 ).

In one exemplary embodiment, a rectangular lower perimeter or first frame member assembly 1230, disposed opposite to the upper edge surface 1220, defines a lower rectangularly-shaped opening 1230′. The rectangular lower perimeter frame member 1230 includes a proximal longitudinal frame member 1232 and a distal longitudinal frame member 1234. First lateral frame member 1236 and second lateral frame member 1238 are disposed respectively at first end 1201 and second end 1202 and interconnect with proximal longitudinal frame member 1232 and distal longitudinal frame member 1234, respectively, at the opposing ends 1201 and 1202 of the proximal longitudinal frame member 1232 and distal longitudinal frame member 1234 to define the lower rectangularly-shaped opening 1230′.

The chassis 1210 further includes a second frame member assembly 1260 that is exemplarily illustrated, e.g., in FIG. 10 , as a rectangularly-shaped frame member assembly, that is similar in configuration to the first frame member assembly 1230. The second frame member 1260 includes an upper longitudinal frame member 1262 and a lower longitudinal frame member 1264. First lateral frame member 1266 and second lateral frame member 1268 are disposed respectively at first end 1201 and second end 1202 and interconnect with upper longitudinal frame member 1262 and lower longitudinal frame member 1264, respectively, at the opposing ends 1201 and 1202 of the upper longitudinal frame member 1262 and lower longitudinal frame member 1264, to define a rectangularly-shaped opening 1260′.

The cooling sub-assembly or chassis 1200 further includes a pair of heat exchange support members each having an irregularly-shaped polygonal profile defining a plurality of edge surfaces. First heat exchange support member 1242 is disposed in proximity to the first end 1201 and the second heat exchange support member 1244 is disposed in proximity to the second end 1202. The first heat exchange support member 1242 and the second heat exchange support member 1244 are each configured such that the profile of the support members 1242 and 1244 at least partially conforms to the configuration of the upper supporting frame member 1210. along first edges 1242 a, 1244 a and second edges 1242 b, 1244 b, respectively.

First heat exchange support member 1242 and the second heat exchange support member 1244 each further include third edges 1242 c, 1244 c, fourth edges 1242 d, 1244 d, and fifth edges 1242 e, 1244 e, respectively.

The chassis 1200 further includes a proximal longitudinal heat exchange support member 1248 a and a distal longitudinal heat exchange support member 1248 b. The proximal longitudinal heat exchange support member 1248 a has a curved cross-sectional profile that conforms to the contour of third edges 1242 c, 1244 c to enable at least partial interface between the proximal longitudinal heat exchange support member 1248 a and the third edges 1242 c, 1244 c in the vicinity of the first end 1201 and the second end 1202, respectively. The proximal longitudinal heat exchange support member 1248 a includes a longitudinal edge 1249 a that is configured to interface with, and be supported by, forced-convection receiving member 1224 of upper supporting frame member 1210. Similarly, distal longitudinal heat exchange support member 1248 b includes a longitudinal edge 1249 b that is configured to interface with, and be supported by, upper edge surface member 1220 of upper supporting frame member 1210.

The distal longitudinal heat exchange support member 1248 b has a J-shaped cross-sectional profile that enables at least partial interface between the distal longitudinal heat exchange support member 1248 a and the third edges 1242 c, 1244 c in the vicinity of the first end 1201 and the second end 1202, respectively.

The chassis 1200 may further include a first end panel member 1240 that is configured to be disposed in the vicinity of first end 1201. Similarly, chassis 1200 may further include a second end panel member 1246 that is configured to be disposed in the vicinity of second end 1202. The first end panel member 1240 and the second end panel member 1246 each support the upper supporting frame member 1210 in the following manner.

The first end panel member 1240 and the second end panel member 1246 each have a first edge 1240 a, 1246 a that is configured to interface with, and support, upper edge surface 1220 in the vicinity of first end 1201 and second end 1202.

Similarly, the first end panel member 1240 and the second end panel member 1246 each have a second edge 1240 b, 1246 b that is configured to interface with, and support, forced-convection receiving member 1224 in the vicinity of first end 1201 and second end 1202.

Additionally, the first end panel member 1240 and the second end panel member 1246 each have a third edge 1240 c, 1246 c that is configured to interface with, and support, lateral edge member 1222 in the vicinity of first end 1201 and second end 1202.

The first end panel member 1240 and the second end panel member 1246 each have a fourth edge 1240 d, 1246 d that is configured to interface with, and support, first lateral frame member 1236 of first frame member assembly 1230 by fourth edge 1240 d in the vicinity of first end 1201 and second lateral frame member 1238 of first frame member assembly 1230 by fourth edge 1246 d in the vicinity of second end 1202.

Additionally, the first end panel member 1240 and the second end panel member 1246 each have a fifth edge 1240 e, 1246 e that is configured to interface with, and support, first lateral frame member 1266 of second frame member assembly 1260 by fifth edge 1240 e of in the vicinity of first end 1201 and second lateral frame member 1268 of second frame member assembly 1260 by fifth edge 1246 e in the vicinity of second end 1202.

As described above, the chassis 1200 is further configured to receive at least one heat exchange member. More particularly, referring particularly to FIG. 9B, FIG. 9D, FIG. 10 and FIG. 14 , in one exemplary embodiment, the chassis 1200 further includes first and second heat exchange members, e.g., heat exchangers 1270 and 1280 that are flat plate type coil heat exchangers disposed physically parallel to one another within a volume 1290 defined by the upper supporting frame member 1210, the first frame member assembly 1230, the second frame member assembly 1260 and the first end panel member 1240 and the second end panel member 1246 when assembled and interconnected together as described above.

The first and second heat exchangers 1270 and 1280 are supported in proximity to the first end 1201 on inner surface 1242′ of the first heat exchange support member 1242 in proximity to and along the fourth edge 1242 d.

Similarly, the first and second heat exchangers 1270 and 1280 are supported in proximity to the second end 1201 on an inner surface (not shown) of the second heat exchange support member 1244 in proximity to and along the fourth edge 1244 d.

As best illustrated in FIG. 14 , the configuration of the first and second heat exchange support members 1242 and 1244 enable the first and second heat exchangers 1270 and 1280 to be mounted at an angle 1 with respect to the upper edge surface member 1220 (or with respect to the horizontal direction X illustrated in FIG. 9A or FIG. 14 ) to define a slope of the first and second heat exchangers 1270 and 1280. The angle 1 may be generally midway between the angle Θ that defines the slope of the forced-convection receiving member 1224.

As can be appreciated from the foregoing, the upper supporting frame member 1210 defines a longitudinal dimension L and an upper width dimension W2 of the upper edge surface member 1220, while the lower frame member 1230 defines a lower width dimension W1 which is greater than W2.

The chassis 1200 may further include a fluid section 1300 having a rectangular configuration that is designed to interface with the second frame member assembly 1260 and extends distally towards the distal portion 1214. Upper longitudinal frame member 1302 and lower longitudinal frame member 1304 of fluid section 1300 interface with upper longitudinal frame member 1262 and a lower longitudinal frame member 1264 of the second frame member assembly 1260, respectively.

Similarly, first lateral frame member 1306 and second lateral frame member 1308 of fluid section 1300 are disposed respectively at first end 1201 and second end 1202 and interconnect with upper longitudinal frame member 1302 and lower longitudinal frame member 1304, respectively, at the opposing ends 1201 and 1202 of the upper longitudinal frame member 1302 and lower longitudinal frame member 1304 to define a rectangularly-shaped opening 1300′ that interfaces with aperture 1260′ of the second frame member 1260.

Fluid section 1300 includes a first refrigerant fluid supply header 1310 and a first refrigerant fluid return header 1320 that extend longitudinally in the rectangularly-shaped opening 1300′ to and from the first and second ends 1201 and 1202, respectively.

Additionally, fluid section 1300 also includes a second refrigerant fluid supply header 1330 and a second refrigerant fluid return header 1340 that extend longitudinally in the rectangularly-shaped opening 1300′ to and from the first and second ends 1201 and 1202, respectively.

The first and second refrigerant fluid supply headers 1310 and 1330 and first and second refrigerant fluid return headers 1320 and 1340 penetrate through and are supported by the second lateral frame member 1308 at the second end 1202. As additional cooling sub-assemblies or chassis 1200 are added to the data center to form a chain of cooling sub-assemblies or chassis 1200, first and second refrigerant fluid supply headers 1310 and 1330 and first and second refrigerant fluid return headers 1320 and 1340 may be extended in a continual or series configuration to penetrate through and to be supported by the first lateral frame member 1306 at the first end 1201.

A first refrigerant fluid supply branch connection 1350 taps off the first refrigerant fluid supply header 1310 to form a refrigerant supply connection end 1352 which is fluidly coupled to refrigerant fluid inlet supply connection 1272 of the first heat exchanger 1270. As the refrigerant fluid removes heat from air originating in the hot space(s) 1150 a, 1150 b . . . 1150 n, the heated refrigerant fluid is discharged from the first heat exchanger 1270 via refrigerant fluid outlet return connection 1274, which in turn is fluidly coupled at first refrigerant return connection 1374 to first refrigerant fluid return branch connection 1370 that taps off the first refrigerant fluid return header 1320.

Similarly, second refrigerant fluid supply branch connection 1360 taps off the second refrigerant fluid supply header 1360 to form a refrigerant supply connection end 1362 which is fluidly coupled to refrigerant fluid inlet supply connection 1282 of the second heat exchanger 1280. Again, as the refrigerant fluid removes heat from air originating in the hot space(s) 1150 a, 1150 b . . . 1150 n, the heated refrigerant fluid is discharged from the second heat exchanger 1280 via refrigerant fluid outlet return connection 1284, which in turn is fluidly coupled at second refrigerant return connection 1384 to second refrigerant fluid return branch connection 1380 that taps off the second refrigerant fluid return header 1340.

Thus, the first heat exchanger 1270 and the second heat exchanger 1280 are fluidically independent of one another with respect to the flow of refrigerant fluid. However, the first heat exchanger 1270 and the second heat exchanger 1280 are fluidically in series with one another with respect to the air flow passing across the coils that originates from the hot space(s) 1150 a, 1150 b . . . 1150 n.

The chassis 1200 may further include further include a first control box 1410 that is coupled to the distal side of the fluid section 1300 via hinges 1412 and may further include further include a second control box 1420 that is coupled to the distal side of the fluid section 1300 via hinges 1422. The control boxes 1410 and 1420 may be rotatably coupled to the distal side of the fluid section 1300 to facilitate maintenance operations. The control boxes may contain instrumentation and control circuits and power cabling for the forced convection members 1250. Thus the fluid section(s) 1300 may also provide functionality as electrical sections.

FIG. 11 partially illustrates the forced convection members 1250 in the cooling sub-assembly or chassis 1200 as mounted above a server rack enclosure 1010 a. Penetration spaces 1430 and 1440 for power or instrumentation and control cabling are positioned below the upper supporting frame member 1210.

FIGS. 12A and 12B illustrate a shroud member 1500 that is configured to be positioned at the first end 1201 and aligned with the cooling assembly or chassis 1200 as particularly illustrated in FIGS. 1, 2 and 11 . Shroud member 1500 is also illustrated in FIGS. 3A, 3B and 3C. A mirror image shroud member 1500′ (see FIGS. 3A, 3B, 3C; partially shown in FIG. 1 ) similarly may be configured to be positioned at the second end 1202 and aligned with the cooling sub-assembly or chassis 1200.

The shroud 1500 includes a rectangularly-shaped lower base plate member 1502 having first and second longitudinal edges 1504 a and 1504 b and first and second lateral edges or ends 1506 a and 1506 b, respectively. A rectangularly-shaped plate member 1508 defines a first lateral edge 1508′ that is disposed to interface with the second lateral edge 1506 b of the lower base plate member 1502. A second lateral edge 1508″ extends vertically upward at a right angle to the plate member 1502. In addition, the rectangularly-shaped plate member 1508 defines a first longitudinal edge 1508 a and a second longitudinal edge 1508 b each extending vertically upward.

A contoured S-shaped or slide shaped longitudinal panel member 1514 defines a first lateral edge 1514′ that intersects with the first lateral edge 1506 a of the plate member 1502. The panel member 1514 includes a first partially curved horizontal portion 1514 a defining the first lateral edge 1514′, an intermediate portion 1514 b that slopes upwardly, and a second partially curved horizontal portion 1514 c that defines a second lateral edge 1514″.

Thus, the longitudinal panel member 1514 slopes upwardly such that the second lateral edge 1514″ intersects with second lateral edge 1508″ of the rectangularly-shaped plate member 1508. As a result, the second lateral edge 1514″ is at an elevated position as compared to the first lateral edge 1514′

A contour-matching vertical plate member 1510 a extends vertically from the first longitudinal edge 1504 a of the lower plate member 1502 to intersect first longitudinal edge 1516 a of the panel member 1514.

A first partially contour-matching vertical plate member 1510 b extends vertically from the second longitudinal edge 1504 b of the lower plate member 1502 to intersect with second longitudinal edge 1516 b of the panel member 1514. The vertical plate member 1510 b extends along the length of first partially curved horizontal portion 1514 a to a lateral edge 1510 b′.

A second vertical plate member 1518 defines a first longitudinal edge 1518′ and a second longitudinal edge 1518″ that intersects at a right angle with the second longitudinal edge 1508 b of the rectangularly-shaped plate member 1508.

The second vertical plate member 1518 also defines a first lateral edge 1518 a that intersects with a portion of the second longitudinal edge 1504 b of the lower plate member 1502 and a second lateral edge 1518 b that intersects with a portion of the second longitudinal edge 1514 b of the longitudinal panel member 1514.

Thus the lateral edge 1510 b′ of the first partially contoured plate 1510 b, the second longitudinal edge 1516 b of the longitudinal panel member 1514 that extends along the intermediate portion 1514 b and partially along the second partially curved horizontal portion 1514 c, the first longitudinal edge 1518′ and a portion of the second longitudinal edge 1504 b of the lower panel member 1502 that extends from the lateral edge 1510 b′ to the first longitudinal edge 1518′ define an aperture 1520 of an internal volume 1520′ defined within the shroud member 1500.

FIG. 13 , as previously described, illustrates the cooling sub-assemblies or chassis 1200 mounted above the server rack enclosure sub-assemblies 1100.

FIG. 14 is a cross-sectional view of one of the cooling assemblies 1000 to illustrate the flow of heated air in the direction of arrow A from the servers (not shown) in the server racks (not shown) as the heated air enters the hot space(s) 1150 a, 1150 b . . . 1150 n and is drawn upward as shown by the arrow B to the suction side of the forced convection members 1250 first passing through the first and second coil heat exchangers 1270 and 1280, respectively where the air is cooled and heat is removed and discharged to the refrigerant circuit as described above with respect to the cooling sub-assemblies or chassis 1200. As illustrated by arrows C, the air is discharged from the forced convection members 1250 and circulates downwardly in the direction of the arrows D to return as cold air entering the server racks to again cool the servers.

Thus, those skilled in the art will recognize and understand that the aforementioned components of chassis 1200 define structure that is configured to receive at least one heat exchange member, e.g., first and second heat exchangers 1270 and 1280, that exchange heat between a refrigerant fluid flowing through the one or more heat exchange members 1270 and 1280 and heated air or gas that removes heat from at least one server and (not shown) which flows through the confined hot space(s) 1150 a, 1150 b . . . 1150 n.

FIG. 15 is a schematic diagram of a cooling system 100 for cooling server racks in a data center 10 that includes a plurality of cooling assemblies 1000 and a central cooling circuit 1600 according to one embodiment of the present disclosure. The central cooling circuit 1600 is fluidically coupled to the first refrigerant fluid supply header 1310 and first refrigerant fluid return header 1320 and to the second refrigerant fluid supply header 1330 and second refrigerant fluid return header 1340 of the fluid sections 1300 (see FIGS. 9A, 9B, 9C, 9D and 10 ) that may be extended throughout the data center 10.

The central cooling circuit 1600 is configured to enable independent refrigerant flow and temperature control to the first refrigerant fluid supply header 1310 and first refrigerant fluid return header 1320 and to the second refrigerant fluid supply header 1330 and second refrigerant fluid return header 1340. The central cooling circuit 1600 may include, but is not limited to, the dual cooling systems described in international application publication WO 2011/16532 A1 “SPACE-SAVING HIGH-DENSITY MODULAR DATA CENTER AND ENERGY-EFFICIENT COOLING SYSTEM” by Keisling et al. and in international application publication WO 2012/118553 A1 “SPACE-SAVING HIGH-DENSITY MODULAR DATA POD SYSTEMS AND ENERGY-EFFICIENT COOLING SYSTEMS” by Keisling et al. The entire contents of both of these applications are incorporated herein by reference. Regardless of the type of central cooling circuit 1600, the cooling capacity of the central cooling circuit 1600 is adjustable when the cooling load is increased as additional cooling assemblies 1000 are deployed within the data center.

FIG. 16A is a perspective view of a plurality of cooling sub-assemblies 1200 for cooling servers in server racks according to another embodiment of the present disclosure. FIG. 16B is an elevation end view of the plurality of cooling sub-assemblies 1200 of FIG. 16A and FIG. 16C is an elevation view of the plurality of cooling sub-assemblies 1200 of FIGS. 16A and 16B.

More particularly, FIG. 16A illustrates an existing data center 50 having a central ceiling 52 mounted above a hot aisle 20. The data center 50 includes a plurality of existing servers in existing server rack enclosures 200 a, 200 b . . . 200 n-1, 200 n.

Openings, which are not directly visible, are formed in the central hot aisle ceiling 52 to enable the cooling sub-assemblies 1200 to be mounted in the openings to interface with the lower rectangularly-shaped openings 1230′ of the rectangular lower perimeter frame members 1230, thereby enabling circulation of cooling air through the existing data enclosures 200 a, 200 b . . . , 200 n-1, 200 n by operation of the cooling assemblies in a similar manner as described above with respect to FIG. 14 .

As best illustrated in FIGS. 16A and 16C, the cooling sub-assemblies 1200 are mounted in the central hot aisle ceiling 52 in an alternating pattern such that the pluralities of forced convection members 1250 alternately face to the right side of the hot aisle 50 and the left side of the hot aisle 50.

As illustrated in FIG. 16B, hot air flows into the hot aisle 50 and upwardly through the alternating cooling sub-assemblies 1200 to be forced through the heat exchangers 1270 and 1280 (see FIG. 10 ) and is recirculated back to the plurality of existing servers in existing server rack enclosures 200 a, 200 b . . . 200 n-1, 200 n as shown by the arrows E.

Thus, the cooling sub-assemblies 1200 may be easily retrofitted into existing data centers, in conjunction with the installation of the central cooling circuit 1600 to form a cooling system analogous to cooling system 100 for cooling server racks as described above with respect to FIG. 15 .

Accordingly, the energy consumption and power cost expenditures for existing data centers may be substantially reduced by the embodiments of the present disclosure.

While several embodiments of the disclosure have been shown in the drawings and/or described in the specification, it is not intended that the disclosure be limited to these embodiments. It is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims set forth below. 

What is claimed is:
 1. A cooling assembly for cooling server racks comprising: a server rack enclosure sub-assembly comprising: at least one panel member defining a volume for receiving one or more server racks having a front portion and a rear portion, at least one of the one or more panel members is a rear panel member; at least one frame member defining an opening for receiving the rear portion of the one or more server racks to form a hot space between the rear panel member and the combination of the at least one frame member and the rear portion of the one or more server racks; a cooling sub-assembly disposed in thermal communication with the hot space to enable cooling of at least one server supported in the at least one server rack, the cooling sub-assembly comprising a chassis configured to receive at least one heat exchange member for exchanging heat between a refrigerant fluid flowing through the at least one heat exchange member and fluid flowing through the hot space that has been heated by the at least one server. 